Models LP301A, LP301A-SSP LP301A-4000, LP600 and LP

Transcription

1 Models LP301A, LP301A-SSP LP301A-4000, LP600 and LP Triplex Ceramic Plunger Pump Operating Instructions/ Manual Updated 07/18 Contents: Installation Instructions: page 2 LP301A/LP600 Specifications: page 3 Exploded View: page 4 Parts List: page 5 Repair Kits: page 6 Repair Instructions: page 7-10 Pump Mounting Selection Guide: page 10 Torque Specifications: page 10 Trouble Shooting/Preventative Maintenance Check-List & Recommended Spare Parts List: page 11 Dimensions: back page Warranty Information: back page

2 INSTALLATION INSTRUCTIONS Operation and Maintenance Check oil level prior to starting and ensure trouble free water supply. IMPORTANT! If there is a danger of frost, the water in the pump and in the pump fittings (particularly the unloader valve) must be emptied. The second discharge port can also be used and the pump run dry for 1-2 minutes for this purpose. Oil: Use only 118 fluid ounces (3.5 L) of SAE 90 Industrial gear lube oil. (Giant s p/n 01154) Initial change after 50 operating hours and then every 1000 operating hours, or after one year if used less. Caution! When operating in damp places or with high temperature fluctuations, condensate (frothy oil) might occur in the gear box. In this situation, change the oil immediately. Keep NPSH under control. Maximum input pressure is 145 PSI (10 bar), the maximun suction head is PSI (-0.3 bar). Make sure that suction pulsation is sufficiently dampened. Water column resonance must be avoided. Safety Rules Pump operation without safety valve as well as any excess in temperature or speed limits automatically voids the warranty. The safety valve must be regulated in accordance with the guidelines for liquid spraying units so that the admissible operating pressure can not be exceeded by more than 10%. When the pump is in operation, the open shaft end must be covered up by a shaft protector (21). For direct drive operations, the driven shaft side and coupling must have a guard over the connected area. Pressure in discharge line and in pump must be at zero before any maintenance to the pump takes place. Close the fluid supply to the inlet port(s). Disconnect fuses to ensure that the driving motor does not accidentally get switched on. Make sure that all parts on the pressure side of the unit are vented and refilled, with pressure at zero, before starting the pump. In order to prevent air, or air/water mixture being absorbed and to prevent cavitation occurring, the pump-npshr, positive suction head and water temperature must be kept under control. Required NPSH refers to water: Specific weight lb/ft 3 (1kg/dm 3 ), viscosity 1 E at maximum permissible revolutions. Cavitation and/or compression of gases lead to uncontrollable pressure kicks which can ruin pump and unit parts and also be dangerous to the operator or anyone standing nearby. Giant pumps are suitable for pumping clean water and other non-aggressive or abrasive media with a specific weight similar to water. Before pumping other liquids - especially inflammable, explosive and toxic media - the pump manufacturer must under all circumstances be consulted with regard to the resistance of the pump material. It is the responsibility of the equipment manufacturer and/or operator to ensure that all pertinent safety regulations are adhered to. NOTE: Contact Giant Industries for Service School Information. Phone: (419)

3 Model LP301A/LP301A-SSP/LP301A-4000 Specifications U.S. Metric Ratings (continuous) RPM LPM Ratings (intermittent)* RPM LPM Power Required (continuous) BHP kw Power Required (intermittent)...50 BHP kw Inlet Pressure to 145 PSI to 10 Bar Plunger Diameter mm Stroke mm Crankcase Oil Capacity fl.oz Liters Temperature of Pumped Fluids o F...60 o C Inlet Port...1-1/4 BSP Discharge Port...1 BSP Crankshaft Mounting...Either Side Shaft Rotation... Top of Pulley Towards Fluid End Weight lbs...54 kg Crankshaft Diameter mm NPSHR ft.-head mws U.S. Metric Volume...Up to 9.8 GPM...37 LPM Discharge Pressure PSI Bar Power Required BHP kw Inlet Pressure to 145 PSI to 10 Bar Speed RPM Plunger Diameter mm Stroke mm Crankcase Oil Capacity fl.oz liters Temperature of Pumped Fluids o F...60 o C Inlet Port...1-1/4 BSP Discharge Port...1 BSP Crankshaft Mounting...Either Side Shaft Rotation... Top of Pulley Towards Fluid End Weight lbs...54 kg Crankshaft Diameter mm NPSHR ft.-head mws *Intermittent duty for pump speeds in excess of 805 RPM PULLEY INFORMATION Pulley selection and pump speed are based on a 1725 RPM motor and B section belts. When selecting desired GPM, allow for a ±5% tolerance on pumps output due to variations in pulleys, belts and motors among manufacturers. 1. Select GPM required, then select appropriate motor and pump pulley from the same line. 2. The desired pressure is achieved by selecting the correct nozzle size that corresponds with the pump GPM. LP301A PULLEY SELECTION AND HORSEPOWER REQUIREMENTS RPM GPM 2500 PSI 3000 PSI 3500 PSI 4000 PSI * * Model LP600/LP Specifications 3 HORSEPOWER INFORMATION We recommend that a 1.15 service factor be specified when selecting an electric motor as the power source. To compute specific pump horsepower requirements, use the following formula: HP = (GPM PSI) / 1450 LP600 PULLEY SELECTION AND HORSEPOWER REQUIREMENTS GPM RPM 3000 PSI 4000 PSI 5000 PSI 5800 PSI * Intermittent duty only

4 Exploded View LP301A/LP301-SSP/LP301A-4000/LP600/LP Important! The stainless steel valve plugs (48) can seize when being screwed out of the casing. To release tension beforehand, strike the plugs 1-2 times with a steel hammer on the top before screwing them out. Coat threads with antiseize (e.g. Fel-Pro Nickel Anti-Seize 51119) 4

5 Parts List ITEM PART DESCRIPTION QTY Crankcase Oil Filler Plug Assembly Cover Plate 1 3A Spring Ring 2 3B Hexagon Screw Crankcase Cover O-ring, Crankcase Cover Oil Sight Glass w/gasket Oil Dipstick Assembly O-Ring, (For Dipstick) Cylinder Screw (LP600/LP301A) Cylinder Screw, 316 S.S. (LP /LP301A-4000) Spring Ring (LP600/LP301A) Spring Ring, 316 S.S. (LP /LP301A-4000) Plug, G1/2 (LP600/LP301A) Plug, G1/2, 316 S.S. (LP /LP301A-4000) O-Ring Bearing Cover Radial Shaft Seal O-Ring for Bearing Cover Hexagon Screw (LP600/LP301A) Hexagon Screw, 316 S.S (LP /LP301A-4000) Taper Roller Bearing 2 20A Shim, 0.1 mm B Shim, 0.15 mm C Shim, 0.2 mm (May not be present) Shaft Protector 1 21A Shaft Guard Holder Crankshaft Key Connecting Rod Assembly 3 24A Inner Hex Screw 6 24B Spring Washer Crosshead Assembly Crosshead Pin 3 29A Centering Sleeve 3 29B Plunger Pipe (LP600/LP ) 3 29B Plunger Pipe (LP301A/LP301A-4000) 3 29B SS Hard Metal Plunger (LP301A-SSP) 3 29C Tensioning Screw 3 29D Copper Ring (LP600/LP301A) 3 29D 07161A-0100 Crush Washer (LP /LP301A-4000) Oil Scraper Oil Seal Seal Sleeve (LP600/LP ) Seal Sleeve (LP301A/LP301A-4000) Leakage Seal (LP600/LP ) Leakage Seal (LP301A/LP301A-4000) Seal Case (LP600/LP ) Seal Case (LP301A/LP301A-4000) O-Ring, Seal Case 3 38A Support Ring for 38 3 ITEM PART DESCRIPTION QTY O-Ring (LP600/LP ) O-Ring (LP301A/LP301A-4000) 3 39A Support Ring for 39 (LP600/LP ) 3 39A Support Ring for 39 (LP301A/LP301A-4000) V-Sleeve (LP600/LP ) V-Sleeve (LP301A/LP301A-4000) 6 40A Pressure Ring (LP600) 3 40A Pressure Ring, 316 S.S. (LP ) 3 40A Pressure Ring (LP301A) 3 40A Pressure Ring, 316 S.S (LP301A-4000) 3 40B Support Ring for 40 (LP600) 3 40B Support Ring for 40, 316 S.S. (LP ) 3 40B Guide Ring for 40 (LP301A) 3 40B Guide Ring for 40, 316 S.S. (LP301A-4000) 3 40C Sleeve (LP600/LP ) Pressure Spring (LP301A/LP301A-4000 Only) Valve Casing 1 44A O-Ring 9 44B Support Ring for O-Ring Compression Spring Valve Assy.,Complete (LP600/LP ) Valve Assy., Complete (LP301A/LP301A-4000) 6 46A Valve Seat (LP301A/LP301A-4000) 6 46A Valve Seat (LP600/LP ) 6 46B Valve Plate (LP600/LP ) 6 46B Valve Plate (LP301A/LP301A-4000) 6 46C Valve Spring 6 46D Spacer Pipe (LP301A/LP301A-4000) 6 46D Spacer Pipe (LP600/LP ) 6 46E Valve Spring Guide (LP600/LP ) Plug Stud bolt 8 49A Hexagon Nut 8 49B Disc Plug, 1/2 BSP, S.S. (LP301A/LP301A-4000 Only) 1 50A Steel Ring Disc for Crankshaft Hexagon Screw * Plug, 1 BSP * Plug, 1-1/4 BSP 1 *BSP to NPT Adapters/Seals (sold separately) Inlet Port = (Adapter) / (Seal) Discharge Port = (Adapter) / (Seal) + rated up to 3000 PSI. For higher pressure adapters, contact Giant. 5

6 Repair Kits LP301A - # For pumps manufactured on or after 4/ Leakage Seal O-Ring 3 38A Support Ring O-Ring 3 39A Support Ring V-Sleeve 6 40A Pressure Ring 3 Plunger Packing Kits LP301A # Leakage Seal O-Ring 3 38A Support Ring O-Ring 3 39A Support Ring V-Sleeve 6 40A Pressure Ring 3 LP600 - # Leakage Seal O-Ring 3 38A Support Ring O-Ring 3 39A Support Ring V-Sleeve 3 40A Pressure Ring 3 40C Sleeve 3 LP # Leakage Seal O-Ring 3 38A Support Ring O-Ring 3 39A Support Ring V-Sleeve 3 40A Pressure Ring 3 40C Sleeve 3 LP301A/LP301A # A O-Ring 6 44B Support Ring 3 46A Valve Seat 3 46B Valve Plate 3 46C Valve Spring 3 Valve Kits LP301A/LP301A # 09196A 44A O-Ring 9 44B Support Ring 3 46A Valve Seat 6 46B Valve Plate 6 46C Valve Spring 6 LP600/LP # A O-Ring 6 44B Support Ring 3 46A Valve Seat 3 46B Valve Plate 3 46C Valve Spring 3 LP600/LP # 09195A 44A O-Ring 9 44B Support Ring 3 46A Valve Seat 6 46B Valve Plate 6 46C Valve Spring 6 Oil Seal Kit - # Oil Seal 3 6

7 TO CHECK VALVES REPAIR INSTRUCTIONS NOTE: Always take time to lubricate all metal and non-metal parts with a light film of oil before reassembling. This step will help ensure proper fit, at the same time protecting the pump non-metal parts (elastomers) from cutting and scoring. 44B 44A 45 1) Loosen and remove tension plugs (48) with a 36mm socket wrench. 2) Remove the support ring (44B), O-ring (44A) and tension spring (45). 3) Take out discharge valve assemblies (46) by pulling them upwards out of the valve casing (43) with a snap-ring tongs or any other pull-off device. Then remove inlet valves in the same way. 46C 46A 46D 46B 4) Loosen valve seats (46A) and valve spring (46C) from spacer pipe (46D) by lightly hitting the valve plate (46B) with a plastic stick. LP600/LP pumps have an additional valve spring guide (46E). Check sealing surface and replace worn parts. Reassemble with new O-rings (44A) if possible and oil them before installing. 5) Tighten up tension plugs (48) to 107 ft.-lbs. (145 NM) 7

8 REPAIR INSTRUCTIONS NOTE: Always take time to lubricate all metal and non-metal parts with a light film of oil before reassembling. This step will help ensure proper fit, at the same time protecting the pump non-metal parts (elastomers) from cutting and scoring. TO CHECK SEALS AND PLUNGER PIPE 6) Loosen the 8 nuts (49A) with a 19mm socket and pull off valve casing (43) to the front. 7) Remove the seal sleeve (35) from the manifold and /or crankcase. 8) Remove seal case (37) from seal sleeve (35) A 37 38A 38 9) Check O-rings (39 & 38) and support rings (39A & 38A) on seal case (37) A B (40C in LP600) 10) Remove leakage seal (36) from the seal sleeve. If worn or damaged replace with new seal. 11) Remove the pressure ring (40A), v-sleeves (40), sleeve (40C in LP600 only), and support ring (40B), from the seal sleeve. For LP301A and LP301A-4000 pumps, remove the pressure spring (41). Examine seals carefully and replace if worn. Clean surfaces of seal sleeves (35) which come in contact with the crankcase (1) and sealing surfaces of valve casing (43). 8

9 REPAIR INSTRUCTIONS 29B 29D 29C Weep Hole 12) Check plunger surface (29B). If plunger pipe is worn out, loosen tension screws (29C) with a 15mm socket and pull off plunger pipe to the front. Clean front surface of plunger (29B) thoroughly. Apply a small drop of locktite to tension screw. Put a new crush washer (29D) onto tension screw. Put a thin coat of glue (Loctite) on the ring (or ceramic plunger side) and tighten screw to 265 in.-lbs. (30 NM). 13) Replace complete seal sleeve (35)/seal case (37) assembly into crankcase (1). Make sure that the weep hole points downward. Note: To replace the oil seals (31), you will need to disassemble the gear end (see instructions below) ) Place entire manifold/seal sleeve assembly over the studs and push firmly until seated against the crankcase. 15) Tighten hex nuts (49A) in a crosswise pattern (shown above) to 59 ft.-lbs. (80 Nm). 9

10 REPAIR INSTRUCTIONS TO DISMANTLE GEAR END After removing valve casing (43) and plunger pipe (29B), drain the oil. Remove the gear cover (4) and both bearing covers (14). Loosen connecting rod screws (24A) and push the front of the connecting rod (24) forward as far as possible into the crosshead guide. IMPORTANT! Connecting rods (24) are marked for identification. Do not twist connecting rod halves. Connecting rod is to be reinstalled in the same position on shaft journals. Turning the crankshaft (22) slightly, hit it out carefully to the side with a rubber hammer. IMPORTANT! Do not bend the connecting rod (24) shanks. Check crankshaft (22) and connecting rod (24) surfaces, radial shaft seals (15) and taper roller bearings (20). To remove the oil seals (31) use a wooden rod and sharply hit down on the oil seals from the crankcase (1). Note: when replacing the oil seals, apply a small amount of locktight to the outside edges of each oil seal before re-inserting them into the crankcase. To Reassemble Using a soft tool, press in the outer bearing ring until the outer edge lines up with the outer edge of the bearing hole. Remove bearing cover (14) together with radial shaft seal (15) and o-ring (16). Fit crankshaft (22) through bearing hole on the opposite side. Press in outer bearing and tighten it inwards with the bearing cover, keeping the crankshaft in vertical position and turning slowly so that the taper rollers of the bearings touch the edge of the outer bearing ring. Adjust axial bearing clearance to at least 0.1mm and maximum 0.15mm by placing fitting discs (20A and 20B) under the bearing cover. IMPORTANT! After assembly has been completed, the crankshaft should turn easily with very little clearance. Tighten connecting rod screws (24A) to 22 ft.-lbs. (30 Nm) Re-assemble the fluid end (see instructions above). TORQUE SPECIFICATIONS Position Item# Description Torque Amount Crankcase (Molycoate-Copper Paste on sealing area - seal sleeves) Oil Sight Glass w/gasket (Loctite 572) 29 ft.-lbs. (40 Nm) / Cylinder Screw 221 in.-lbs. (25 Nm) Plug, 1/2 BSP 29 ft.-lbs. (40 Nm) / Hexagon Screw 221 in.-lbs. (25 Nm) 24A Inner Hex Screw, Connecting Rod 22 ft.-lbs. (30 Nm) 29C (LP600) Tension Screw, Plunger (Loctite 243) 22 ft.-lbs. (30 Nm) 29C (LP301A) Tension Screw, Plunger (Loctite 243) 26 ft.-lbs. (35 Nm) 29D Copper Ring (Loctite 577 on both sides) 29D Crush Washer (Loctite 577 on both sides) Oil Seal (Loctite 403) Plug, Discharge (Pro Pack 550) 107 ft.-lbs. (145 Nm) Stud Bolt (Small amtount on crackcase side Loctite 270) 49A Hexagon Nut, Stud Bolts 59 ft.-lbs. (80 Nm) Pump Mounting Selection Guide Bushings mm H Bushing Pulley & Sheaves Cast Iron - 4 gr. AB Section Rails Plated Steel Channel Rails (L=11.75 x W=1.88 x H=3.00 ) 10

11 Pump System Malfunction MALFUNCTION CAUSE REMEDY The Pressure and/ Worn packing seals Replace packing seals or the Delivery Broken valve spring Replace spring Drops Belt slippage Tighten or Replace belt Worn or Damaged nozzle Replace nozzle Fouled discharge valve Clean valve assembly Fouled inlet strainer Clean strainer Worn or Damaged hose Repair/Replace hose Worn or Plugged relief valve on pump Clean, Reset, and Replace worn parts Cavitation Check suction lines on inlet of pump for restrictions Unloader Check for proper operation Water in crankcase High humidity Reduce oil change interval Worn seals Replace seals Noisy Operation Worn bearings Replace bearings, Refill crankcase oil with recommended lubricant Cavitation Check inlet lines for restrictions and/or proper sizing Rough/Pulsating Worn packing Replace packing Operation with Inlet restriction Check system for stoppage, air Pressure Drop leaks, correctly sized inlet plumbing to pump Accumulator pressure Recharge/Replace accumulator Unloader Check for proper operation Cavitation Check inlet lines for restrictions and/or proper size Pressure Drop at Gun Restricted discharge plumbing Re-size discharge plumbing to flow rate of pump Excessive Worn plungers Replace plungers Leakage Worn packing/seals Adjust or Replace packing seals Excessive vacuum Reduce suction vacuum Cracked plungers Replace plungers Inlet pressure too high Reduce inlet pressure High Crankcase Wrong Grade of oil Giant oil is recommended Temperature Improper amount of oil in crankcase Adjust oil level to proper amount Preventative Maintenance Check List & Recommended Spare Parts List Check Daily Weekly 50 hrs Oil Level/Quality Oil Leaks Water Leaks Belts, Pulley Plumbing Recommended Spare Parts 11 Every 500 hrs Oil Change (1 Gallon) p/n Oil Seal Kit (1 kit/pump) (see page 6 for kit list) Seal Spare Parts (1 kit/pump) (see page 6 for kit list) Valve Spare Parts (1 kit/pump) (see page 6 for kit list) Every 1500 hrs Every 3000 hrs

12 Dimensions (mm) - GIANT INDUSTRIES LIMITED WARRANTY Giant Industries, Inc. pumps and accessories are warranted by the manufacturer to be free from defects in workmanship and material as follows: 1. For portable pressure washers and car wash applications, the discharge mani folds will never fail, period. If they ever fail, we will replace them free of charge. Our other pump parts, used in portable pressure washers and in car wash applica tions, are warranted for five years from the date of shipment for all pumps used in NON-SALINE, clean water applications. 2. One (1) year from the date of shipment for all other Giant industrial and consumer pumps. 3. Six (6) months from the date of shipment for all rebuilt pumps. 4. Ninety (90) days from the date of shipment for all Giant accessories. This warranty is limited to repair or replacement of pumps and accessories of which the manufacturer s evaluation shows were defective at the time of shipment by the manufacturer. The following items are NOT covered or will void the warranty: 1. Defects caused by negligence or fault of the buyer or third party. 2. Normal wear and tear to standard wear parts. 3. Use of repair parts other than those manufactured or authorized by Giant. 4. Improper use of the product as a component part. 5. Changes or modifications made by the customer or third party. 6. The operation of pumps and or accessories exceeding the specifications set forth in the Operations Manuals provided by Giant Industries, Inc. Liability under this warranty is on all non-wear parts and limited to the replacement or repair of those products returned freight prepaid to Giant Industries which are deemed to be defective due to workmanship or failure of material. A Returned Goods Authorization (R.G.A.) number and completed warranty evaluation form is required prior to the return to Giant Industries of all products under warranty consideration. Call (419) or fax (419) to obtain an R.G.A. number. Repair or replacement of defective products as provided is the sole and exclusive remedy provided hereunder and the MANUFACTURER SHALL NOT BE LIABLE FOR FURTHER LOSS, DAMAGES, OR EPENSES, INCLUDING INCIDENTAL AND CONSEQUENTIAL DAMAGES DIRECTLY OR INDIRECTLY ARISING FROM THE SALE OR USE OF THIS PRODUCT. THE LIMITED WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATION, EPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WAR- RANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL SUCH WARRANTIES ARE HEREBY DISCLAIMED AND ECLUDED BY THE MANUFACTURER. GIANT INDUSTRIES, INC., 900 N. Westwood Ave., Toledo, Ohio PHONE (419) , FA (419) , Copyright 2018 Giant Industries, Inc. 07/18 LP301A-LP indd